I made it at TechShop.
Only use tools that you have had the appropriate training for. Always wear eye protection when near tools. Understand and accept the inherent risks associated with any operation.
Vertical Belt Sander
Table Router with a 1/8th inch radius bit
Color Printed Paper - 75 cents each
1/8th" 2'x4' MDF - $4
Colored Felt Sheet - 32 cents each
Spray Clear Sealer
Spray Contact Cement
Step 1: Prepare and Print a Design
Some notes on the layout: Don't put lines where you will cut, they will be visible. Remember to bleed any graphics that are supposed to go right up to the edge about an eighth of an inch. About a quarter of an inch of margin reduces the need for exact cutting. Add cut marks on all sides, then chop away. The marks will fall off before you get to use them on one of the sides, that's ok. Pick the scrap off the table- it is a perfect measuring tape for where to cut the rest are. Just line it up and cut it up.
- Coaster Designs - 1 - kanpai.ai
- Coaster Designs - 1 - kanpai.pdf
- Coaster Designs - 3 - limerick.pdf
- Coaster Designs - 4 - Heinlein.pdf
Step 2: Cut MDF
To set a cut length stop on the chop saw, carefully align one of the boards, then slide two pieces of scrap up against the work. Clamp the piece farther from the work to the fence, so that when the other piece of scrap is removed from the sandwitch, there is no pressure on the work. This will keep the blade from binding and damaging the squares when they are cut free.
Step 3: Round Corners
Clamp all the pieces together to form one large block of 'wood'. Use the disk sander to flatten up the three exposed sides. I slid the block from left to right and noticed that this caused a sort of jointer effect, where it would take a slice off. The outside of the disk will sand faster, so a sliding motion ensures more consistent sanding.
Once the edges are sanded flush, run it through the router. Setting the fence close will make the work less awkward to handle. Use a third clamp to facilitate switching the clamps to the other side of the block. Sand the last side flush, then go back to the router to finish the two previously inaccessible corners.
Step 4: Spray Paint and Glue
Secret trick to make the project work:Take the clear spray and apply liberally to the back of the papers. Enough so that it evenly soaks into the paper, and the design can be seen through as pictured. This will help with the water resistance of the paper, but more importantly will keep the paper from becoming clear when applied to the wood. If the paper is not sealed and let dry before being glued on the wood, when applied the sealer will unevenly wet the paper onto the wood, causing it to show through. This action will not go away when the sealer dries.
If you decide that you want to paint the wood a color now is the time to do it. Spray the front, then stack them together to spray the sides. Don't bother with the bottom since it will be covered by the felt.
Glue on the Paper
Apply spray glue to the back of the paper, wait a few seconds, then carefully apply to the wood. Once all the papers are applied a coat of sealer can be applied.